EV BMS with Charging Monitoring & Fire Protection

Abstract

This paper presents the design and implementation of an Electric Vehicle (EV) Battery Management System (BMS) with integrated charge monitoring and fire protection. The increasing adoption of EVs has highlighted the need for advanced battery safety and performance systems, particularly for lithium-ion battery packs which are highly sensitive to electrical and thermal stresses. The proposed system continuously monitors key parameters such as voltage, current, temperature, and state of charge (SOC) using a microcontroller-based architecture. Advanced algorithms are implemented for charge estimation and cell balancing to ensure uniform energy distribution across battery cells. Additionally, thermal management is enhanced through temperature sensing and fire detection modules that identify abnormal conditions such as overheating or gas emission.In hazardous situations, the system activates protection mechanisms including relay-based isolation, alarm systems, and emergency shutdown. The system also supports real-time display and optional IoT-based remote monitoring for improved user awareness and control.Experimental results demonstrate improved safety,efficient charge utilization, and reliable performance under various operating conditions. The proposed BMS provides a scalable and cost-effective solution for next-generation EV battery systems.

Introduction

This paper presents a Battery Management System (BMS) for electric vehicles (EVs) that integrates charge monitoring and fire protection to improve battery safety, efficiency, and lifespan. Lithium-ion batteries are highly sensitive to overcharging, deep discharging, excessive current, and high temperatures, making an effective BMS essential. The system continuously monitors voltage, current, temperature, and State of Charge (SOC) to ensure safe battery operation. Fire protection is enhanced through temperature and gas sensors, which detect abnormal conditions and automatically disconnect the battery while activating alarms.

The literature survey highlights previous research on battery modeling, SOC estimation, thermal management, and thermal runaway prevention, emphasizing the importance of intelligent monitoring systems. Building on these studies, the proposed system combines real-time monitoring with safety mechanisms for comprehensive battery protection.

The system consists of a lithium-ion battery pack, voltage/current/temperature sensors, an Arduino Nano V3 microcontroller, a relay-based protection circuit, fire detection sensors, and an LCD/OLED display. It uses voltage-based and coulomb counting methods for SOC estimation and includes protection against overcharging, over-discharging, overcurrent, and short circuits.

Testing results show accurate voltage monitoring (±1% error), reliable current and temperature measurements, effective SOC estimation, and rapid detection of unsafe conditions. The system successfully prevented overcharging and automatically shut down the battery when the temperature exceeded the safety threshold, demonstrating reliable performance and enhanced battery safety.

Conclusion

The proposed EV Battery Management System with Charge Monitoring and Fire Protection provides a robust solution for improving the safety and efficiency of lithium-ion battery systems. By integrating electrical and thermal monitoring with intelligent control mechanisms, the system effectively prevents hazardous conditions such as overcharging and thermal runaway. The inclusion of fire detection features further enhances safety, making the system suitable for real-world EV applications.

References

[1] IEEEVarious research papers on Battery Management Systems, thermal management, and EV safety.Website: https://ieeexplore.ieee.org [2] National Fire Protection AssociationNFPA 855: Standard for the Installation of Stationary Energy Storage Systems – Fire safety guidelines for battery systems.Website: https://www.nfpa.org [3] Battery UniversityTechnical articles on lithium-ion batteries, charging methods, and safety precautions.Website: https://batteryuniversity.com [4] Texas InstrumentsApplication notes on battery monitoring ICs, BMS design, and protection circuits.Website: https://www.ti.com [5] ResearchGateResearch papers on EV battery safety, IoT-based monitoring, and fire detection systems.Website: https://www.researchgate.net [6] SpringerBooks and journals on electric vehicles, energy storage systems, and safety engineering.Website: https://www.springer.com

Copyright

Copyright © 2026 Ms. Mamta Chavan, Mr. Rehan Shah, Mr. Manoj Rajbhar, Mr. Sagar Shewale, Mr. Rohan Dhanshetty, Mr. Swapnil Jadhav. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.